Method of making thick butt shingles



May 21,1946.` A. A. FAssioTTo 'l2-rm.v

METHOD 0F MAKING THICK BUTT SHINGLES Filed Dec. 8. 1943 2 Sheets-Sheet l TH f I h \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\v TECN; f6 f5 4/9 /6 ,y f /5 BY ATT/@747:

ATTORNEY Patented ITI-:D STATES. PATENT ori-*ICE METHOD F MAKING THICK BUTT SHINGLES Artigues. Fassietto ena George W. stnmk, Jouet, Ill., assignors to The Ruberoid Co., New York, N. Y., a corporation of New Jersey Application December 8, 1943, Serial No. 513,390

4 oieims.

cover the butt only with a second coating of' asphalt and layer of granules. This is subject to theldisadvantage, among others, that the second coat 'is not bonded directly to the base. Another method is to apply one coat of asphalt and layer of granules to the face, and another coat to the back under the butt. While this increases the thickness it does not increase the weather resistance of the butt. It has also been proposed first to apply a coating of one thickness to the butt portion, leaving the lap vportion uncoated, and then to apply a coating of lesser thickness to the lap portion. Still another proposal is to apply a coating of uniform thickness to the entire face of the sheet, surfacing the lap portions with fine granules only and the butt portions with intermingled coarse and fine granules, and differentially pressing the coarse and the fine granules into the coating. This method has the disadvantages that the butt and lap portions are not clearly offset, and that the Weight of the shingle, and particularly the butt portion, cannot be controlled with any reliable degree of accuracy or uniformity. Various otherproposals pertaining to features of thickness of asphalt shingles are set forth at page 658 of Asphalts and Allied Substances, fourth edition, by Herbert Abraham.

In the manufacture of shingles of this character it is important both to control the weight with substantial uniformity, and to provide a attain the desired optical effect, practice has shown that this difference in thickness-should runA in the neighborhood of .05" and andthat the stepup should be pronoimced and' angular.

According to the present invention, the saturated felt sheet is coated on both surfaces, eachv with a single layer of uniform thickness of molten asphalt coating material or other thermo-plastic and thicker portions, however, before molding the A bituminous composition. preferably admixed with suitable fillers. The coating on the front face is molded or shaped to provide alternate thinner coating on the upper face, the coating on the back is temporarily shaped with thicker and thinner portions in inverse relation and opposition to those subsequently formed-on the front face. 'It has been found that this procedure greatly facilitates the formation of distinct shoulders or offsets between the portions of different thickness on the front face. After shaping the coating on the front face, that on the back is removed except for a uniformly thin seal coat. The coating on the front face While still plastic is covered with granules. the granules on the thicker' and thinner portions being partially embedded in said portions respectively by separate pressing operations. i

The invention will be understood from the fol-v lowing description thereof, reference being had to the accompanying drawings, in which: n

Figs. 1 to 8 arev cross-sectional views of a sheet of material illustrating, somewhat diagrammatically, various stages or steps in the method of manufacture of the shingles;

Fig. 9 is a perspective view of one form of thick butt shingle made according to the method;

Fig. 10 is a conventionalized view in elevation of a form of apparatus for carryingout the method; Fig. 11 is a perspective view of portions of the apparatus shown in Fig. 10; and

Fig. 12 is a perspective view of the member of the apparatus that applies the coating of diner-- ential thicknesses to the back of the sheet.

Having reference nowparticularly to Figs. 1 `to 8, l0 indicates a sheet or web of saturated felt of any desired weight, thickness, and width. A coating of asphalt or suitable thermo-plastic compositionis applied to both faces of the sheet, the

coating on the back being indicated by the reference character il, and that on the front by the character l2', in the view illustrated in Fig. 2.- The coating on the back is thenshaped to form alternate thicker portions I3 and thinner portions M, as seen in Fig. 3.V Next the coating on thev f front is shaped to form alternate thinner portions l5 -and thicker portions I6, as shown in Fig.

4'. It-will be seen that the thicker portions on the back are opposite to the tl inner portionsson the front, and vice versa. The coating on the back is then levelled or evened, as indicated in Fig, 5, to leave only a uniform, thin coat Il such as the'usual seal coat on the back of prepared roong shingles.

lstationary, orA the lower one may rotate.

The thicker portions I6 of the front coat constitute the butts of the cut and finished shingles,

one form of which is illustrated in Fig. 10, while the rthinner portions I constitute the -backgrounds, that is, the portions that are lapped when laid. The particular sheet illustrated represents a sheet of 36" width that is intended to be cut longitudinally into three strips each of 12" width, the lines of cutting being indicated by the lines A-A and B-B in Fig. 8. For this reason one of the thicker portions is made twice the width of the others. It is to be understood that the width of the sheet, as well as the Width and shape of the shingles, may be varied since the method may be us'ed to make thick butt shingles of a number of different forms.

After the coating on the front face of the sheet has been shaped, and that on the back partly scraped off, a layer of granules is deposited on the front coat, as depicted in Fig. 6. The granules I8 on the thinner portions may be of the same or of a dlerent character from the granules I9 on the thicker -portions. The former are usually of a cheaper grade, while the latter, which face the exposed portion of the shingles, are commonly of a better grade and generally colored. At this stage of manufacture the granules are not embedded in the coating.

vThe sheet is then subjected to two separate pressing operations by which the granules I9 are first partially embedded in the thicker portions of the coating, and then the granules. I8 are partially embedded in the thinner portions. In this manner relatively sharp shoulders or lines of oiset 20 are formed between said portions as indicated in Figs. l and 8. While it is preferred to press the granules in this order, the order may be reversed.

One form of apparatus for practice of the method is inustrated in' Figs. 1o m12. with use of this apparatus, the sheet of saturated felt I 0 is led over guide rolls 2| and under a dip roll 22 .through a coating pan V23 whereby coatings II and I2 are applied to the two faces of the sheet. The coated sheet as it emerges from the dip pan passes over a former or scraper '24 which may be -cylindrical or of other shape, and which is formed with indentations or depressions 25 in its surface,

` see Fig. 12. This member shapes the back coating I I into thicker and thinner portions I3 and I4. The sheet then passes between two rolls 21 and and thinner portions of the top coat so as to deposit'the granules I8 and I3 on said portions respectively. The plates are set against the drum 3d to direct the return ow of excess granules into the hopper. A coating of mica or the like may be applied to theback coat il from a mica box 35.

The sheet then advances over rolls 36 and 3l to a press section where the granules i9 are partially embedded in the thicker portions IS of the coating. One form of press section is shown in Fig. l0 comprising a drum 38 against which the face of the molded granuled surfaced sheet is pressed by anendless blanket 39 traveling on rolls d0. Any other suitable means, such as tension rolls, or press rolls, may be used for this purpose.

-After passing over cooling drums di the sheet travels between press rolls 42 and 43 that operate to press the granules I8 into the thinner coating portions I5, and by which the shoulders 2t are sharpened. To these ends the upper press roll i2 is formed with portions 44 of enlarged diamthinner portions I5 of the top or frontl coating.

Finally, the sheet after having been textured, if desired, and further cooled by passing over loopers or otherwise, is cut into shingles of the desired shape and size. The means for texturing, looping, and cutting the sheet are not shown in the drawings since they are well known in the art.

Thick butt shingles measuring 12'. by 36" and having three tabs along the exposed edge may be made by the present method to weigh from about 205 to 210 pounds per square, and with a difierential in thickness between butt and background portions of about .05". As hereinbefore noted, variations in the shape, size, weight, and relative i thickness of the parts may be made.

28, one above the other, both of which'may be Bands 29 are positioned around the roll 21 at properly spaced intervals so that as the sheet passes between the rolls the coating I-2 on the top or front face is molded or shaped with alternate thinner and thicker portions I5 and I6.

The member 24 is set adjacent the lower roll 28 with its indented portions 25 disposed opposite tothe bands 29, so that the thicker portions i3` of the back coat will come under the subsequently formed thinner portions I5 of the top coat. v yThe thicker portions on the back tendA to raise the sheet against the bands 29v and thus to provide a more distinct offset or shoulder 2li between the thicker and thinner portions of the top coat.

' The sheet progresses over a scraper edge 3@l that removes all of the back coating save for a uniform, thin seal coat il, and then passes under a hopper 3i and granule feed roll 32l by which a layer of granules is deposited across the width of the top face of the sheet. The hopper is preferably divided by plates 33 into compartments corresponding in number and width to the thicker 'I'heA term shingle and shingles" are used throughout the specication and claims in a comprehensive sense to include strip-shingles or multiple-unit shingles as well as individual shingles.

What we claim is:

1. A method of making thick butt shingles which comprises applying a layer of bituminous coating material of uniform thickness to the face and back of a web of roofing felt, shaping the back coat to form alternate thicker and thinner portions, thereafter, while the web is supported on the thicker portions of the back coat, shaping the face coat to form alternate thickerand thinner portions having a sharp line of demarcation between them, said thicker portions of the face coat constituting the butts of the shingles and being disposed above the thinner portions of the back coat, and then removing the thicker portions of the back coat to leave a seal coat of uniform thickness on the back of the web.

2. A method of making thick butt shingles which comprises applying a layer of bituminous coating material of uniform thickness to the face and the back of a web of roofing belt, shaping the back coatto form alternate thicker and thinner portions, thereafter.. while the web is supported on the thicker portions of the back coat, shaping the front coat to form alternate thicker and thinner portions having a sharp line or dethicker portions `oi the back coat to leave a. seal coat of uniform thickness on the back of the web, depositing granules on the face coat. and

partially embedding the granules separately Vin thethicker and thinner portions thereof.

3. A method of making-thick butt shingles which comprises applying a layer of bituminous coating material of uniform thickness tothe face and the back of a web of roofing feit, shaping the back coat to form alternate thicker and thingies and being disposed above the thinner portions of the 'back coat, then removing the thicker portions of the back coat to leave a seal coat of j uniform thickness on the back of theweb, de'- positing granules on the face`coat, pressing the granules partially into the thicker portions of the face coat, and then pressing the granules partially into the thinner portions. v

4. A method of making thick butt shingles which comprises coating the face and back of a l web of saturated felt each with a single'layer of bituminous material of uniform thickness, shap ing the back coat to form alternate thicker and v thinner portions, thereafter, while the webis supported on the thicker portions of the back coat,

depressing the `face coat at intervals across the j width of the web to form alternate thinner and thicker portions having a sharp line of demarcation between them, the thicker portions of the face coat constituting the butts of the shingles registering substantially with thefthinner portions of the back coat and the thinner portions of the face coat constituting the laps of the shingles registering. substantially with the thicker portions' ci' the back coat, then-scraping oil the thicker portions of the back coat to leave a seal coat of uniform thickness on the back of the web, depositing granules' on the face coat, and partially embedding the granules in the thicker and. thinner portions respectively Vof the face coat.

Amano A. FAssIo'rrQ; GEoRGE W.' s'rRUNK. 

